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Full text of "NHTSA NCAP #00374 1981 Jet Industries Electrica (1981 Mercury Lynx Electric Conversion)"

Report Number to be assigned by NHTSA 



FMVSS 212/219/301 
ELECTRIC VEHICLE TESTING - GROUP V 

JET INDUSTRIES INC. 

1981 Electrica (Mercury Lynx) 



Prepared by: 

DYNAMIC SCIENCE, INC. 
A Talley Industries Company 
1850 West Pinnacle Peak Road 
Phoenix, Arizona 85027 



*J&n&2S$» 







November 1981 

TEST REPORT 



Document is available to the public through the 
National Technical Information Service 
Springfield, Virginia 22161 

Prepared for: 

U.S. DEPARTMENT OF TRANSPORTATION 
OFFICE OF PASSENGER VEHICLE RESEARCH 
NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION 
WASHINGTON, D.C. 20590 



Prepared for the Department of Transportation, National High- 
way Traffic Safety Administration, under Contract No. DOT-HS- 
9-02274, Delivery Order No. 16. This document is disseminated 
under the sponsorship of the Department of Transportation in 
the interest of information exchange. The United States Gov- 
ernment assumes no liability for the contents or use thereof. 



NOTICE 

The United States Government does not endorse products or manu- 
facturers. Trade or manufacturer's names appear herein solely 
because they are considered essential to the object of this 
report. 



TECHNICAL REPORT STANDARD TITLE PAGE 



1, Report No 



2. Government Accession No. 3. Recipient's Catalog No. 



4. Title and Subtitle FMVSS 212, 219, 301 ELECTRIC 
VEHICLE TESTING - GROUP V - 1981 ELECTRICA 
(MERCURY LYNX) 



5. Report Date 
November 1981 



6. Performing Orgn Code 



Author (s) 



N. Johnson , S. Davis 



8, Performing Orgn Rpt No 
3126-81-108/1932 



9. Performing Organization Name and Address 
Dynamic Science, Inc. 
A Talley Industries Company 
1850 West Pinnacle Peak Road 
Phoenix, Arizona 85027 



10. work Unit No; 



11. Contract or Grant No. 
DOT-HS-9-02274, D.O. #16 



12. Sponsoring Agency Name and Address 
U.S. Department of Transportation 
National Highway Traffic Safety Administration 
400 Seventh Street, S.W. 
Washington, D.C. 20590 



13. Type of Report and 
Period Covered 
TEST REPORT 

October 1981 



14. Sponsoring Agency Code 



15. Supplementary Notes 



16. Abstract 

This report presents the results of an electric vehicle to load-measuring 
fixed barrier, head-on crash test. This test was conducted to determine 
if the vehicle would comply with the windshield retention requirements of 
the Federal Motor Vehicle Safety Standard (FMVSS) 212, the windshield zone 
intrusion requirements of FMVSS 219, and the fuel integrity requirements of 
FMVSS 301-75. The standard fixed barrier was replaced by the 36-cell load- 
-measuring fixed barrier. The electric vehicle, a 1981 Electrica {Mercury 
Lynx) , manufactured by Ford Motor Company and altered by Jet Industries 
Inc., was tested on October 21, 1981 at a speed of 30.34 mph. The 1981 
Electrica (Lynx) appears to meet the requirements of FMVSS 212, 219, and 
301. 



17. Key Words 
Load-Measuring Fixed Barrier, Wind- 
shield Retention, Windshield In- 
trusion, Occupant Response, Electric 
Vehicle, Fuel System Integrity 



18. Distribution Statement 

Copies available to the public 
through the National Technical 
Information Service, Springfield, 
Virginia 22161 



19. Security Classif 
(of this report) 
Unclassified 



20. Security Classif. 
{of this page) 

Unclassified 



21. No. Pages 
92 



22. Price 



Form DOT F 1700 .7 (8-69 



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IX 



TABLE OF CONTCNT£J 

Page 

1.0 INTRODUCTION 1-1 

2.0 HIGHLIGHTS OF TEST RESULTS 2-1 

3.0 RESULTS 3-1 

4.0 PHOTOGRAPHIC COVERAGE 4-1 

5.0 CALCOMP PLOT PRESENTATION 5-1 



ill 






1.0 INTRODUCTION 

This report presents the results of an electric vehicle 
to load-measuring fixed barrier, head-on crash test. This 
test was conducted to determine if the vehicle would comply 
with the windshield retention requirements of Federal Motor 
Vehicle Safety Standard (FMVSS) 212, the windshield zone in- 
trusion requirements of FMVSS 219, and the fuel spillage re- 
quirements of FMVSS 301-75. The electric vehicle tested was 
the 1981 Electrica (Mercury Lynx) manufactured by Jet Indus- 
tries Inc. 

Table 1-1 contains a summary of the electric vehicle 
crash test conditions for Test No. 3126-2. 

TABLE 1-1. SUMMARY OF ELECTRIC VEHICLE CRASH TEST CONDITIONS 

Vehicle Model/ Vehicle Closing 
Test Test Dynamic Science Weight Speed 
Date Configuration Number (lb) (mph ) 

10/21/81 Car-to-Load Cell Electrica 3471 30.34 
Barrier, Head-on (Lynx) DSI 1212 

The load cell barrier face is pictured in Figure 1-1. 
The barrier consists of a 9 X 4 array of 50 klb load cells 
each faced with a section of 1-3/4-inch thick plywood. Ply- 
wood sections for Rows C and D (upper two rows) each measure 
ten inches high and nine inches wide. Plywood sections for 
Rows A and B (lower two rows) each measure nine inches high 
and nine inches wide. Overall width of the barrier is 83 
inches and overall height is 38-3/4 inches. The lower edge of 
the barrier is 2-5/8 inches above the surface of the ground. 



1-1 



(UIQI 




I 










pa 

r:; 



1-2 



2.0 HIGHLIGHTS OF TEST RESULTS 

This section of the report highlights the results of the 
three compliance tests (FMVSS 212, 219, and 301-75) conducted on 
the electric vehicle. Paragraphs 2-1 through 2-3 contain general 
FMVSS test and performance requirements followed by summaries of 
the Electrica performance. Section 3.0 presents a detailed sum- 
mary of the structural and dummy performance results obtained. 

2.1 FMVSS 212 - WINDSHIELD RETENTION TESTING 

FMVSS 212 specifies the following requirements: 

"When the vehicle traveling longitudinally forward at any 
speed up to and including 30 mph impacts a fixed collision 
barrier that is perpendicular to the line of travel of the 
vehicle. . .the windshield mounting of the vehicle shall... 
retain not less than 75 percent of the windshield periph- 
ery. " 

(Code of Federal Regulations, Title 49, Section 571.212) 

Summary of the Electrica (Lynx) Performance - 212 Test 

The windshield showed no loss of retention and the vehicle 

consequently appears to meet the requirement of FMVSS 212. 

2.2 FMVSS 219 - WINDSHIELD ZONE INTRUSION 

FMVSS 219 requires that: 

"When the vehicle traveling longitudinally forward at... 30 
mph, impacts a fixed collision barrier that is perpendi- 
cular to the line of travel of the vehicle... no part of the 
vehicle outside the occupant compartment, except windshield 
molding and other components designed to be normally in con- 
tact with the windshield, shall penetrate the protected zone 
template, affixed according to (Standard 219), to depth of 
more than one-quarter inch, and no such part of a vehicle 
shall penetrate the inner surface of that portion of the 
windshield below the protected zone.." 

(Code of Federal Regulations, Title 49, Section 571.219) 

2-1 



Summary of the Electrica (Lynx) Performance - 219 Test 

During the frontal barrier crash, there was no intrusion 
into the windshield protected zone. Therefore, the vehicle 
appears to meet the requirements of FMVSS 219. 



2,3 FMVSS 301 - FRONTAL IMPACT FOR INTEGRITY OF MOTOR VEHICLE 
FUEL SYSTEMS 



FMVSS 301 specifies the following compliance requirements: 

"When the vehicle traveling longitudinally forward at,.. 30 
mph impacts a fixed collision barrier that is perpendicular 
to the line of travel of the vehicle. . .fuel spillage shall 
not exceed a total of five ounces by weight in the five- 
minute period following cessation of motion. For the sub- 
sequent 25-minute period, fuel spillage during any one- 
minute interval shall not exceed one ounce by weight." 

(Code of Federal Regulations, Title 49, Section 571.301-75) 

During the static rollover which follows barrier impact, 

the following requirements must be met: 

"When the vehicle is rotated on its longitudinal axis to 
each successive increment of 90 degrees* . .fuel spillage 
shall not exceed a total of five ounces by weight for the 
first five minutes of testing at each successive 90-degree 
increment. For the remaining testing period, at each 
increment of 90 degrees, fuel spillage during any one- 
minute interval shall not exceed one ounce by weight." 

(Code of Federal Regulations, Title 49, Section 571.301-75) 

Summary of the Electrica (Lynx) Performance - 301 Test 

The vehicle impacted the barrier at a speed of 30.34 mph. 

In the five-minute period following the barrier impact 
there was no fuel leakage. 



2-2 



When the vehicle was placed in the static rollover fix- 
ture and rotated, there was only a trace of fuel leakage 
throughout the test. The vehicle thus appears to meet the 
requirements of FMVSS 301-75. 

2.4 ELECTRICA (LYNX) BATTERY SAFETY 

During impact the front battery box was pushed rearward and 
downward underneath the rear battery box in the engine compart- 
ment. All batteries remained inside the boxes, although some 
were broken, resulting in massive electrolyte leakage. There 
was no leakage into the occupant compartment. 

The battery box in the rear of the vehicle remained intact 
and closed, restraining the batteries in their original posi- 
tions. No leakage occurred from these batteries until the ve- 
hicle was rolled at 180° during the post-test static rollover, 
then approximately one gallon of electrolyte leaked into the 
occupant compartment. 

A small fire occurred after impact in the high-voltage con- 
troller box in the left rear section of the cargo area. It was 
quickly extinguished with a portable fire extinguisher. 



2-3 



3.0 result:' 

This section presents all test results without analysis 
or discussion. Included in this document are: data summary 
sheets for each Federal Motor Vehicle Safety Standard, sum- 
maries of the simulated occupant data including injury cri- 
teria values, tabulated pre- and post-test dimensions, and a 
summary of vehicle accelerometer locations and data. Section 4 
contains pre- and post-test dummy and vehicle photographs. 
High-speed motion pictures were also obtained and have been 
submitted to NHTSA. Section 5.0 contains Calcomp plots for 
all vehicle accelerometer data, occupant response data, seat 
belt loads, and barrier load cell data. 



3-1 



GENERAL TEST AND VEHICLE PARAMETER DATA 



PRE-IMPACT DATA 

Make/Model: Electrica (Lynx) 



Body Style: 3-Door Hatchback , Model Year: 1981 

NHTSA No.; R&D DSI No. 1212 Color; Light Blue 

DATA FROM CERTIFICATION LABEL 



Vehicle Manufacturer; Ford Motor Company/Jet Industries Inc 



Date of Manufacture: 7/81 ; VIN: 1MEBP6327BW636367 



GVWR: 3790 lb; GAWR; Front = 1686 lb; Rear = 2104 lb 

DATA FROM "RECOMMENDED TIRE PRESSURE" LABEL 

Vehicle Capacity: FRONT REAR RECOMMENDED LOAD RANGE: 
Tire Pressure: 35 psi 35 psi TIRE SIZE: STD 

P165/80R13 
Designated Seating: 2 Front 2 Rear 4 Total 

Cargo load = 50 lb Is Spare Tire: Space Saver? No 

TOTAL = 650 lb Standard Equipment? No 

Engine: Electric 

Transmission: 4-Speed Manual, Front-Wheel Drive 

Date Vehicle Received by Laboratory: 8/20/81 ; Odometer: 172.8 
Dealer Name & Address: Jet Industries Inc. 



Austin, Texas 



WEIGHT (LB) OF TEST VEHICLE AS RECEIVED (WITH MAX. FLUIDS) = UDW 

Right Front = 695 1» Right Rear = 777 lb 

Left Front = 708 1b Left Rear = _804 lb 

TOTAL FRONT WEIGHT = 1403 lb { 47.0 % of Total Vehicle Weight) 
TOTAL REAR WEIGHT = 1581 lb ( 53.0 % of Total Vehicle Weight) 
TOTAL DELV. WEIGHT = 2984 lb 
TARGET WEIGHT = UDW + Cargo Load + 328 lbs Dummies = 3362 lb 
WEIGHT OF TEST VEHICLE WITH REQUIRED DUMMIES AND 50 lb CARGO: 
Right Front = 807 lb Right Rear = 928 lb 

Left Front = 796 lb Left Rear = 940 lb 

TOTAL FRONT WEIGHT = 1603 lb ( 46.2 % of Total Vehicle Weight) 
TOTAL REAR WEIGHT = 1868 lb ( 53.8 % of Total Vehicle Weight) 
TOTAL TEST WEIGHT = 3471 lb 

Weight of ballast secured in vehicle trunk area = None lb 
VEHICLE ATTITUDE: (inches) 

Delivered Attitude: RF 29.0 LF 29.0 RR 29.0 LR 29.0 
Test Attitude: RF 28.5 LF 28 .3 RR 28.3 LR 28.3 
REMARKS: Vehicle modified by Jet Industries , Inc. on 8/81. 



3-2 



GENERAL TEST AND VEHICLE PARAMETER DATA (CONT) 
POST-IMPACT DATA 



Type of Test: 
Date of Test: 



Frontal 



10/21/81 



(0° ) Impact 
Time: 1-332 



Required Impact Velocity Range: 

Impact Velocity: Primary = 30. 34 



Temperature 85 <>f 

30 »0 to 31,0 mph 

mph Secondary = 30 . 30 mph 



Distance from the vehicle's front bumper to barrier face entering 
the vehicle velocity measurement device is 5.0 feet and distance 
exiting the vehicle velocity measurement device is 1.0 foot. 



VEHICLE REBOUND AND CRUSH (in.) 
Vehicle Length: Pre-test = R 



160.9 



133.6 



27.3 



163.8 



137.2 



26.6 



160.6 



Post-test = R 
Crush = R 
Distance from front of test vehicle to point of impact: 

R 6.5 £ 4.3 L 
VISIBLE DUMMY CONTACT POINTS 



13.5.8 



24.8 



6.0 



Driver 



Head 

Chest 

Abdomen 
Left Knee 
Right Knee 

DOOR OPENING 



Steering wheel 


rim 


and hub 


Steering wheel 


rim 


Steering wheel 


rim 


Lower dash 


Lower dash 


Front 



Passenger 


Front 


edge of upper 


dash 


None 


None 




Glove 


box 


Glove 


box 


Rear 



Left 



Right 



Left 



Right 



Tools 



Tools 



N/A 



N/A 



SEAT MOVEMENT 

Seatback Failure 

Seat Shift (in. ) 



GLAZING DAMAGE 



Required Required 



None 



None 



3/4" fwd, 
left side 



3/4" fwd, 
right side 



Seat removed before 
test 



Backlight/Windshield Windshield severely cracked along bottom three inches 

and loft side. Moderate cracking of remainder. 

OTHER NOTABLE IMPACT EFFECTS: Extensive buckling of front compart- 



ment 


floor pan, including f 


ront 


and 


rear seat 


crossmember 


s . Both 


seats rotated app 


roximately 


ten 


degrees counte 


rclockwise . 


All 


seat 


mounts bent, 


lowering 


the t 


seats 


Both doors pushed 


rearward 



3-3 



OTHER NOTABLE IMPACT EFFECTS (Continued) : 

over B pillars a n d both front quarter panels pushed rearward under 

neath doors. Right door inner and outer panels separated f with 

outer panel bowing outward. The right sill buckled downward 

severely approximately 15 inches aft of the A pillar. The left 
sill and sheet metal buckled between the B pillar and rear wheel 
well. Both front wheels were pushed rearward and were pinned in 

the sheet metal. The left rear wheel was also pinned in sheet 

metal . The floor pan-to-sill welds failed on both sides from the 
firewall to the front seat rear crossmember. 



3-4 






SUMMARY OF FMVSS 212 DATA 
PRE-IMPACT DATA 

Make/Mode 1 : Electrica (Lynx) 



Body Style: 3-Door Hatchback Model Year: 1981 

NHTSA No. R&D DSI No. 1212 Color: Light Blue 

DATA FROM CERTIFICATION LABEL 

Vehicle Manufacturer: Ford Motor Company/Jet Industries Inc . 
Date of Manufacture: 7/81 ; VIN 1MEBP6327BW636367 



GVWR: 3790 lb? GAWR: Front = 1686 lb; Rear 2104 lb 
POST-IMPACT DATA 

Type of Test: Frontal (0°) Impact 

Date of Test: 10/21/81 Time: 1332 Temperature 85 °F 

Required Impact Velocity Range: 30.0 to 31-0 mph 

Impact Velocity: Primary = 30.34 mph Secondary = 30.30 mph 

Test weight: 3471 lb Static crush: 26. 6 in. 

Rebound distance: 4.3 in. 

DETAILS OF WINDSHIELD MOUNTING: Windshield is bonded on all sides by 
b lack mastic 1.7 inch wide at bottom, 1 inch on sides, 1.3 inch at top. The 

periphery is overlaid by 5/8 inch wide metal trim. No retainer clips are 

visible. . 



WINDSHIELD PERIPHERY 





Pre-test 


Post-test 


RIGHT SIDE 


69.5 


69.5 


LEFT SIDE 


69.5 


69.5 


***TOTAL*** 


139.0 


139.0 



The standard requires that POST-TEST be a minimum of 75 percent of 
the PRE-TEST total periphery measurement for vehicles not equipped 
with occupant passive restraints and 50 percent for each side of 
the windshield for vehicles which are equipped with occupant pas- 



sive restraints. 



3-5 



SUMMARY OF FMVSS 212 DATA (CONTD) 

AREA OF RETENTION FAILURE: None. Severe cracking in bottom 
three inches. Entire windshield cracked. 




FRONT VIEW 



3-6 



SUMMARY OF FMVSS 219 DATA 



PRE-IMPAOT DATA. 

Make/Model: Electrica (Lynx 

Body Style: 

NHTSA No, 



3-Door Hatchback 



R&D 



DSI No 



1212 



Model Year: 1981 
Color: Light Blue 



DATA FROM CERTIFICATION LABEL 

Vehicle Manufacturer; Ford Motor Company/Jet Industries Inc 
Date of Manufacture: 7/81 VIN 1MEBP6327BW636367 
GVWR: 3790 



lb; 



GAWR: Front = 1686 



lb; 



Rear 2104 



lb 



POST-IMPACT DATA 

Type of Test: . Frontal 
Date of Test: 



10/21/81 



(0°) Impact 
Time: 1332 



Temperature 

to 31.0 



_ - 85 °F 

Required Impact Velocity Range: 30. to 31. mph 

Impact Velocity: Primary = 30. 34 mph Secondary = 30 .30 mph 
3471 lb 



Test weight: 

Rebound distance: 



Static crush: 



26.6 



in 



4.3 



in. 




11.75" 



FPONT VIEW OF WINDSHIELD 



A. The area that the "Protected Zone" template was penetrated 
more than 0.25 inch by a vehicle component other than one 
which is normally in contact with the windshield. 

Coordinates 



X 

N/A 



N/A 



3-7 



SUMMARY OF FMVSS 219 DATA (CONTD) 

B, The area beneath the "Protected Zone" that the inner surface 
of the windshield was penetrated by a vehicle component, 

Coordinates 
X Y 

N/A N/A 



3-8 



PRE-IMPACT DATA 



Make/Model 
Body Style 
NHTSA No. : 



Electrica (Lynx) 



3-Door Hatchback 



Model Year: 1981 



R&D 



DSI No 



1212 



Color: Light Blue 



7/81 



VIN: 1MEBP6 3 27BW63 6 3 67 



DATA FROM CERTIFICATION LABEL 

Vehicle Manufacturer: Ford Motor Company/Jet Industries Inc 
Date of Manufacture^ 
GVWR: 3790 lb; 

POST- IMPACT DATA 

Type of Test: Frontal 



GAWR: Front - 1686 lb; Rear = 2104 ib 



Date of Test: 10/21/81 
Required Impact Velocity Range: 



_ ( 0°) Impact 
Time: 1332 



30.0 



Temperature 
to 31.0 



85 



mph 



Impact Velocity: Primary = 30. 34 mph Secondary = 30.30 mph 
Test Weight 3471 lb Static Crush 26.6 in. Rebound 4.3 in. 



FUEL SYSTEM DATA 

Specific Gravity: 0, 764 

Kinematic Viscosity: 0.99 centistokes Test Volume: 1.7 U.S» gal 



Test fluid: Red Stoddard Solvent 
Tempe r a tu re : 70 



Test vehicle fuel tank filled to 93% of "usable" plus "unusable" 
capacity with Stoddard Solvent and with electric fuel pump operat- 
ing (if it will operate without engine operation) until start of 
static roll. 

Details Of fuel system: The 2.5-gallon rectangular metal fuel tan k is bolted 
underneath the floor pan in fr ont of the right side of the rear axle. The filler 
opening is located in the right rear quarter panel aft of the wheel. The fill tube 
is routed underneath the car into the rear of the tank. The fuel line exits the 
front of the tank and is routed to the center tunnel and up to the engine fir ewa 1 1 
and heater. 



FUEL SPILLAGE MEASUREMENT 



t^ t 




(t^+5) + 25 



1. From impact until vehi- 
cle motion ceases. • . 

2. For 5-minute period 
after vehicle motion 
ceases 

3. For next 25 minutes. . 



ACTUAL 


MAXIMUM 
ALLOWABLE 





1 OZ 





5 oz 





1 oz/1 min 



SOLVENT SPILLAGE DETAILS: None 



3-9 



FMVSS 301-75 STATIC ROLLOVER DATA SHEET 



TEST PHASE 



o 



to 90 



o 



VEHICLE: Electrica (Lynx) 




Fuel Filler 
Cap Location 



■ 


*■** H 


^ 






s fo 




'»'i 


• 


L ■ 




r.jr 


^^Jli^l^.^* - *' 







NOTE: If side fill, 
rotate so that filler 
cap is down , 

DETERMINATION OF SOLVENT COLLECTION TIME PERIOD: 

. = 1 min, 39 sec + 



Rollover Fixture 90° Rotation Time 
(Spec. Range = 1 to 3 minute) 



FMVSS 301 Position Hold Time 
Total 



mm, 



21 



sec 



7 min, sec 



FMVSS 301 REQUIREMENTS AND ACTUAL TEST RESULTS: 

First 5 min 

(from onset) 6th min 7th min 



Time 
Period 



8th min 
(if req'd) . 



Maximum 
Spillage 
Allowed 
(oz) 


5 


1 


1 


1 


Actual 

Spillage 

Recorded 











— 



NOTE: Spillage is recorded in whole minute intervals only - 
as determined above. 

SOLVENT SPILLAGE LOCATION (S): None. 



3-10 



FMVSS 301-75 STATIC ROLLOVER DATA SHEET 



TEST PHASE: 90 to 180 VEHICLE : Electrica (Lynx) 





DETERMINATION OF SOLVENT COLLECTION TIME PERIOD: 

. = 1 min, 35 sec + 



Rollover Fixture 90° Rotation Time 
(Spec. Range - 1 to 3 minute) 



FMVSS 301 Position Hold Time 
Total 



min 



nan, 



2 5 sec = 
sec 



FMVSS 301 REQUIREMENTS AND ACTUAL TEST RESULTS: 



Time 
Period 



First 5 rain 
(from onset) 



6th min 



7th min 



8th min 
(if req'd) 



Maximum 
Spillage 
Allowed 
(oz) 


5 


1 


1 


1 


Actual 

Spillage 

Recorded 











— 



NOTE: Spillage is recorded in whole minute intervals only - 
as determined above. 

SOLVENT SPILLAGE LOCATION (S): None. Approximately one gallon 
of electrolyte leaked from the rear batteries into the rear oc- 
cupant compartment. 



3-11 



FMVSS 301-75 STATIC ROLLOVER DATA SHEET 



TEST PHASE: 180 to 270° VEHICLE; Electrica (Lynx 





DETERMINATION OF SOLVENT COLLECTION TIME PERIOD: 

- 1 min, 37 sec + 



Rollover Fixture 90° Rotation Time ♦ 
(Spec, Range = 1 to 3 minute) 



FMVSS 301 Position Hold Time 
Total ..... 



5 min 



7 min, 



23 sec = 
sec 



FMVSS 301 REQUIREMENTS AND ACTUAL TEST RESULTS: 

6th min - 7th min 



Time 
Period 



First 5 rain 
(from onset) 



8th min 
(if req'd) 



Maximum 










Spillage 
Allowed 


5 


1 


1 


1 


(oz) 










Actual 










Spillage 
Recorded 











-""" 



NOTE: Spillage is recorded in whole minute intervals only - 
as determined above. 

SOLVENT SPILLAGE LOCATION(S): None. 



3-12 



<*<\. 



FMVSS 301-75 STATIC ROLLOVER DATA SHEET 



TEST PHASE: 270 to 360 VEHICLE: Electri 



ca (Lynx) 





DETERMINATION OF SOLVENT COLLECTION TIME PERIOD: 

1 min, 3 9 sec + 



Rollover Fixture 90° Rotation Time . . 
(Spec. Range = 1 to 3 minute) 



FMVSS 301 Position Hold Time 
Total 



min, 



mm, 



21 sec = 
sec 



FMVSS 301 REQUIREMENTS AND ACTUAL TEST RESULTS: 

6th min 



Time 
Period 



First 5 min 
(from onset) 



7th min 



8th min 
(if req'd) 



Maximum 
Spillage 
Allowed 
(oz) 


5 


1 


1 


1 


Actual 

Spillage 

Recorded 














NOTE: Spillage is recorded in whole minute intervals only 
as determined above. 

SOLVENT SPILLAGE LOCATION (S) : None. 



3-13 



PART 572 DUMMY IN-VEHICI.E POSITION RECORDING SHEET 



PRE- IMPACT DATA 

Make/Modal: Electrica (Lynx) 
Body Style:_ 
NHTSA No. 



3-Door Hatchback 



Model Year: 1981 



R&D 



DSI No. 1212 



Color: Light Blue 



DATA FROM CERTIFICATION LABEL 

Vehicle Manufacturer: Ford Mot or Company /Jet Industries Inc. 
Date of Manufacture 
GVWR: 3790 



7/81 



VIN 1MEBP63 27BW63 6 367 



lb; 



GAWR: Front 



1686 



lb; 



Rear 2104 lb 



POST-IMPACT DATA 

Type of Test: Frontal (0°) Impact 

Date of Test: 10/21/81 Time: 1332 Temperature 85 °F 

Required Impact Velocity Range: 30.0 to 31.0 mph 

Impact Velocity: Primary = 30.34 mph Secondary = 30.30 mph 
Seat Type: Bucket Adjuster Type: Manual 



Bucket Seat Back Type: Fixed 
Technicians: 



N. Johnson, M. Rodack 



HEAD 
TARGET 

KNEE 
JOINT 

APPROX- 
IMATE 

POiNT 



DUMMY* 


A 


8 








22.1 


o 




24 










32.4 


M 




92 






MIDPOINT 



PASSENGER DUMMY « A 9 



23.0 




HEAD 
TARGET 

KNEE 
JOINT 



" APPROX- 
° IMATE 

"H" 

POINT 



MIDPOINT 



OVERALL 



LATERAL BAR 

ADJUSTABLE - 
POINTER 




LEFT 

FRONT 

DOOR 



A 



O 



•* *' 







y? 



- 14.0" 
3 4.0" 



DOOR 

GLASS 

HEIGHT 



DRIVER 
DUMMY 



PASSENGER 
DUMMY 



RIGHT 
FRONT 
DOOR 



A [0 | 8 



A 





9 



3-14 



PART 572 DUMMY IN-VEHICLE POSITION RECORDING SHEET 
STRUCK VEHICLE (CONTD) 



Driver Passenger 




HH 17. n 


14.3" 


HW 21.0" 


20.0" 


CD 22.0" 


20.0" 


CS 13.8" 


N/A 


KD L-4.3 R- 


•4 .0 L-3.5 R 


ES N/A 


N/A 


EBT N/A 


N/A 


EBB N/A 


N/A 


ERS N/A 


N/A 


Torso 
Angle 22 ° 


Torso 
Angle 18 ° 


Seat Back 
Angle 23 ° 


Seat Back 
Angle 20 ° 



HH = Head to Windshield Header 

HW = Head to Windshield 

CD = Chest to Dash 

CS = Chest to Steering Wheel 

KD = Knees to Dash 

ES = Ear to Seat Back 

EBT = Ear to Backlight Top 

EBB » Ear to Backlight Bottom 

ERS = Ear to Rear Seat Back 

HR = Head to Side Roof 

HS = Head to Side Window 

AD = Arm to Door 

HD = Hip to Door 

KK = Knee to Knee 

Torso and seat back angles 

are relative to vertical, 

REMARKS: Dum mie s positio ned 
according to OVSC recommended 
procedure for posi tioning 
Part 572 dummies~I n~tes t"~~ 
ve h i c 1 e . ™ 






Driver 


Passenqer 


HR 


6.5 


6.5 


HS 


7.8 


8.0 


AD 


3.5 


3.5 


HD 


6.0 


5.9 


KK 


10.0 


10.0 


AA 


11.0 


11.0 



3-15 



DUMMY DATA SUMMARY 



Driver Dummy 



Positive 
Direction* 



Negative 
Direction** 



Head Acceleration 
Longitudinal 

Lateral 

Vertical 

Resultant 



Peak 
(G) 



36,9 

9.5 
101.3 
224.4 



Time 
(msec) 



23 

41 
87 
82 



Peak 
(G) 



220.0 

42.7 
39.8 



Time 
(msec) 



Passenger Dummy 

Positive Negative 
Direction* Direction** 



Peak 
(G) 



Time 
(msec) 



Peak 
(G) 



Time 
(msec) 



82 

77 
82 



15.0 124 



23.1 
39.6 
60.0 



109 

106 
110 



46.4 

8.2 
2.3 



111 

125 
8 



HIC 



1237.6 between 81 and 84 msec 269.8 between 62 and 128 mse 



Chest Acceleration 

Longitudinal 
Lateral 
Vertical 
Resultant (Max) 
Resultant (clip) 



4.9 

2.6 

7.5 

35.0 

31.3 



110 
88 
41 
91 
67 



33.4 
18.2 
19.5 



91 
95 
86 



3 
15 
15 
32 
31 



TIME > 60 G 



152 
58 

44 
64 
62 



30.6 

5.5 
14,7 



64 
83 
88 



msec 



msec 



SEVERITY INDEX 

Femur Loads 
Left 
Right 



Belt Loads 
Lap 
Torso 



♦Longitudinal; 
Lateral: 
Vertical: 



207.3 @ 200 msec 



155.9 @ 200 msec 



Peak 
(lb) 

123.7 
106.5 



Time 
(msec) 

48 

51 



Peak 
(lb) 

572.0 
1380.4 



Time 
(msec) 

41 
61 



Not monitored 
Not monitored 



Forward 

Rightward 

Downward 



Peak 
(lb) 

35.1 
56.2 



Time 
(msec) 

22 
120 



Peak 
(lb) 

813.5 
402.8 



514.9 
1381.4 



55 
62 



6.9 
7.9 



Vehicle Impact Speed (mph): 30.34 



Time 
(msec) 

44 
66 



141 
8 



**Longitudinal: 
Lateral: 
Vertical: 



Rearward 
Leftward 
Upward 



3-16 



l 



DRIVER - The driver dummy moved straight forward 



mately 65 msec following the impact 
suddenly dropped (probably when the 
floor pan-to-sill welds failed) and 
counterclockwise (as did the entire 
ing wheel was pushed 
three inches just as 
downward. The dummy 
the upper wheel rim 



Th 

seat 

rota 

seat 

rearward and upward 

the dummy's head wa 

hit the top of its 

and then hit the hub 



The dummy rebounded upward 
rest upright in the seat. 



and rearward, 



for approxi- 
e dummy then 

mounts and 
ted slightly 
) . The steer- 
approximately 
s starting 
forehead on 
with its face 
coming to 



PASSENGER - The passenger dummy moved straight forward until 
approximately 57 msec after impact. The dummy then 
dropped lower in the car as the right sill f which was 
buckling, failed. The dummy's head and torso rotated 
forward and the top of its head struck the front edge 
of the dash. The dummy disappeared completely from 
view (below the edge of the window) from 105 to 155 
msec. It then rebounded back up and rearward into the 
seat, coming to rest leaning slightly to its left. 



OTHER COMMENTS - The left seat 

during impact. Both 

ward and rotated counterclockwise 

degrees. 



back did not appear to latch 

seats moved 3/4 to one inch for- 
approximately ten 



3-17 



VEHICLE PROFILE DATA SHEET 

PRE- IMPACT DATA 

Make/Model : Electrica (Lynx) 

Body Style: 3-Door Hatchback Model Year: 1981 

NHTSA No.; R&D DSI No. 1212 Color: Light Blue 

DATA FROM CERTIFICATION LABEL 

Vehicle Manufacturer; Ford Motor Company/Jet Indust ries Inc. 
Date of Manufacture: 7/81 ? VIN: 1MEBP6327BW636367 



GVWR: 3790 lb; GAWR: Front = 1686 lb; Rear = 2104 
POST-IMPACT DATA 



lb 



Type of Test: Frontal (0°) Impact 

Date of Test: 10/21/81 Time: 1332 Temperature 85 °F 

Required Impact Velocity Range: 30,0 to 31.0 mph 

Impact Velocity: Primary = 30.34 mph Secondary = 30.30 mph 

Measurements Referenced to Plane 14 Feet Forward of Rear Bumper £ 



Vehicle L eft (in,) Vehicle Right (in .) 
Location Height "~ ~" 

-iL. _1±_ _J^_ ._§_ £ 8 16 24 28 



Pre- test Profile (in.) 



Top Of Front 2 0.1 7.4 6.8 4.9 4.4 4.3 4.4 49 6 5 7 1 

Bumper 

Front of 30 . 9 - 12.8 11.3 10.9 10.8 10.8 11.3 12.8 
Hood 



Post-test Profile (in.) 



BuSper Fr ° nt 19 * 6 32 * 3 31 " 8 3 °' 6 3 °* 8 31 " 1 31 - 5 32 '° 33 * 5 34 * 4 

Front Of 28.8 - 32.8 32.5 33.0 32.6 33.1 33.5 33.6 

Hood 



Post- test Static Crush (in.) 



Sper Fr ° nt °* 5 24 " 9 25 '° 2S ' 7 26 ' 4 26 ' 8 27 - 5 27 -! 27 -^ 27.3 

Front Of 2.1 - 20.0 21.2 22.1 21.8 22.3 22.2 20.8 

Hood 



3-18 



PRE- /POST- TEST STATIC MEASUREMENT DATA 







t«if«i/i«ri n««) 



Vehicle: Electrica (Lynx) 
Test Date: 10/21/81 



NHTSA No. : R&D 
D.S. No.: 



1212 



Reference 

Dimension 



x 7 



X B 



c 10 



*14 
X 15 
X 16 
Y 17 
2 18 
X 19 
x 20 
x 21 



Pre-test 
Measurement 

163.8 



109.5 



109.2 



64.5 



64.2 



63.0 



124.0 

124.2 

94.5 

13.0 

15.5 

160.9 

160.6 



6.8 



Post- test 
Measurement 

137.2 



102.1 



101.3 



60.1 



56.1 



56.8 



115.3 

114.0 

85.0 

12.0 

16.8 

133.6 

135.8 



6.8 



Change 
26.6 



X 2 


138.5 


122.7 


15.8 


x 3 


124.3 


111.5 


12.8 


x 4 


109.0 


101.5 


7.5 


x 5 


108.7 


100.1 


8.6 



7.4 



7.9 



4.4 



8.1 



6.2 



x ll 


63.0 


54.8 


8.2 


x 12 


107.3 


99.5 


7.8 


X 13 


108.0 


99.3 


8.7 



8.7 

10,2 

9.5 

1.0 

1.3 

27.3 

24.8 



0.0 



3-19 



VEHICLE ACCELEROMETER LOCATIONS AND SUMMARY 




Component ^ 

Location Direction* X 

No, Description X Y Z '"+" 



Data Summary 
Peak G @ msec 



2 Firewall (above 
steering column) 



3 Firewall (at 
Vehicle (J) 



Front Seat Front 



Crossmember 



Front Seat Rear 
Crossmember) 



/ 



1 Engine (Underside) / y 34.6 99.9 

41 25 



/ / 30.5 73.2 

45 33 



/ / 



38.5 109.0 

52 35 



21.9 64.6 
75 38 



/ 3.7 33.0 

109 58 



15.9 26.4 
27 46 



37.1 • 66.5 
43 39 



16.2 33.7 
31 47 



16.3 17.7 
41 78 



♦Positives X = Forward Y = Rightward 

Negative: X = Rearward Y = Leftward 



2 = Downward 
Z = Upward 



3-20 



4.0 PHOTOGRAPHIC COVRRAGK 

This section consists o£ pre-test and post-test photographs 
of the overall vehicle, windshield, fuel system, and occupants. 



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4-17 




4-1:8 



5.0 CALCOMP PLOT PRESENTATION 

Calcomp plots generated from the crash test data are pre- 
sented on the following pages. All data will be recorded on 
magnetic tape for inclusion in the NHTSA crash test data base 
system. All data was filtered according to SAE J211. Plot 
legends and test anomalies are listed below: 

PLOT LEGEND 

Dummy Data* 

RF Outboard 
Driver Passenger Data Description 

LP Head RF Head Head Acceleration (G) 

LF Chest RF Chest Chest Acceleration (G) 

LF Femurs RF Femurs Femur Loads (lb) 

RF Belt Loads Torso and Lap Belt Loads (lb) 

Vehicle Data** 

Location 



Loc 1 Engine (Underside) Acceleration (G) 
Loc 2 Firewall (Above Steering Column) Acceleration (G) 
Loc 3 Firewall (At Vehicle Centerline) Acceleration (G) 
Loc 4 Front Seat Front Crossmember (Right Side) Accelera- 
tion (G) 
Loc 5 Front Seat Rear Crossmember (Left Side) Acceleration (G) 

Barrier Data 

Columns 1-9 Force (lb) 

Sum A&B Force (lb) 

Sum C&D Force (lb) 

Total Load Force (lb) 

Total Force (Barrier) Versus Displacement (Location 5) 

*Dummy Injury Summary presented on pages 3-16 and 3-17, 
**Vehicle accelerometer location and data summarized on page 3-20. 



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